Automated poultry hanging system and method

ABSTRACT

This invention relates to automated systems and methods for hanging live poultry for further processing. The system has an alignment conveyor, an alignment stunner, a hanging box, a vacuum system and a shackle. The alignment conveyor conveys poultry from an input point to the alignment stunner. The alignment stunner urges the poultry to move to a desired position on the alignment conveyor and stuns the poultry. The hanging box grasps the stunned poultry and places the poultry into the shackle for further processing. A computer and at least one sensor control operation of the system so that human intervention is minimized

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation-in-part application of copending U.S.patent application Ser. No. 14/635,014, filed on Mar. 2, 2015, whichclaims the benefit of U.S. patent application Ser. No. 13/539,384, filedJun. 30, 2012, which claims the benefit of U.S. Provisional ApplicationNo. 61/502,934, filed on Jun. 30, 2011, each of which applications areherein incorporated by reference in their entirety.

FIELD OF THE INVENTION

This invention relates to systems and methods for hanging live poultry.More particularly, this invention relates to automated systems andmethods for hanging live poultry for processing.

BACKGROUND OF THE INVENTION

Poultry processing plants have become automated to a large extent. Dueto Federal regulations, it is necessary to kill the birds while they arein an inverted configuration, so that the blood is pumped from thebirds' body via their own heart. Typically, birds are processed in aninverted position with their hocks suspended by shackles pivotallymounted to an overhead conveyor line. This orientation places the tailregion roughly midway down the bird body while the pivotal mountingenables the birds to be manipulated along the process line. It is commonpractice to electrically stun the birds prior to processing them whilethey are inverted and shackled. In this manner, the birds, while alive,remain relatively motionless for processing.

Conventionally, suspending the bird from the shackles is a manualprocess. For example, depending on the speed to the overhead conveyorline, several employees can be required to restrain the bird, orient thebird correctly relative to the shackles of the conveyor, and place thebird into the shackles. Because the birds are alive, manually loadingthe birds into the shackles can be a cumbersome and unsanitary task.Therefore, there is a need in the industry for a system or apparatus toautomatically hang live poultry for processing. The present inventionfulfills these needs and provides further related advantages as describeherein.

SUMMARY

The application relates to systems and methods for automatically hanginglive poultry, such as a chicken, quail, turkey, duck and the like. Inone aspect, the system for hanging live poultry can comprise at leastone of an alignment conveyor, an alignment stunner, a rain stunner, ahanging box, and a shackle. The alignment conveyor can convey poultryfrom an input point in the processing facility to the alignment stunner.In another aspect, the alignment stunner can urge the poultry to move toa desired position on the alignment conveyor. In still another aspect,the alignment and/or the rain stunner can stun the poultry while thepoultry is in the desired position. In another aspect, the hanging boxcan grasp the stunned poultry and place the poultry into the shackle forfurther processing. In one aspect, it is contemplated that a computercan be configured to control operation of the system so that humanintervention is minimized. The system can also comprise at least onesensor that is operatively coupled to the computer.

Additional advantages of the invention will be set forth in part in thedescription which follows, and in part will be obvious from thedescription, or may be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

DETAILED DESCRIPTION OF THE FIGURES

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 is a schematic diagram of an automated system for hanging livepoultry, according to one aspect.

FIG. 2 is a perspective view a portion of the system of FIG. 1.

FIG. 3 is a cross-sectional side view of a hanging box of the system ofFIG. 1.

FIG. 4 is a perspective view of the hanging box of FIG. 3, showing abird being grasped by the hanging box.

FIG. 5 is a perspective view of a shackle of the system of FIG. 1,showing a bird hanging from the shackle.

FIG. 6 is a side elevational view of a shackle, according to one aspect.

FIG. 7 is a perspective view of the hanging box of FIG. 3.

FIG. 8 is a schematic diagram of an automated system for hanging livepoultry, according to one aspect.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this invention is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,as such can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “a hanging box” can include two or more suchhanging boxes unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The application relates to systems and methods for automatically hanginglive poultry, such as a chicken, quail, turkey, duck and the like. Inone aspect, as illustrated in FIG. 1, the system 10 for hanging livepoultry can comprise at least one of an alignment conveyor 12, analignment stunner 14, a hanging box 16, a vacuum system 17 and a shackle18. As will be described more fully below, the alignment conveyor and/orthe alignment stunner can urge the birds to face a predetermineddirection. The hanging box can then grasp the bird and place it in theshackle for further processing.

In one aspect, the alignment conveyor 12 can be an endless conveyor thatcan be conventionally trained around a plurality of conveyor rollers. Itis contemplated that the endless conveyor can comprise a conventionaldesign. In one non-limiting example, at least one of the conveyorrollers can be driven by a motor or drive, which causes the alignmentconveyor to rotate about the conveyor rollers at a desired andselectable alignment conveyor speed in an alignment conveyor direction.As illustrated in FIG. 2, in another aspect, during at least a portionof the course of the endless conveyor path, at least a portion of thealignment conveyor 12 direction can be substantially linear along analignment conveyor axis. In yet another aspect, during at least aportion of the course of the endless conveyor path, an upper surface 20of the alignment conveyor can be positioned in a conveyor plane that issubstantially parallel to a floor on which the alignment conveyor isplaced. Optionally, during at least a portion of the course of theendless conveyor path, the conveyor plane can be positioned at an acuteangle relative to the floor on which the alignment conveyor 12 isplaced. For example, a first side 22 of the alignment conveyor can behigher than a second side 24 relative to the floor.

Still with reference to FIG. 2, the alignment conveyor 12 can compriseat least one alignment box 26 comprising a first portion 28 and aseparate second portion 30. In one aspect, the first portion and thesecond portion of the alignment box can be fixedly attached to and/orformed on portions of the upper surface 20 of the alignment conveyorsuch that the first and second portions 28, 30 of the alignment boxextend upwardly away from the conveyor plane of the alignment conveyor.In another aspect, when the first and second portions of the alignmentbox 26 are on the upper surface 20 of the alignment conveyor 12, thefirst and second portions can form an enclosure 32 defining a sideopening. As can be appreciated, it is contemplated that respectiveportions of the alignment box 26 can be formed from separate pieces sothat the portions of the alignment box can separate or otherwise segmentapart as respective portions of the upper surface of the alignmentconveyor move relative to each other during the course of the movementof the alignment conveyor around the conveyor rollers. In still anotheraspect, and without limitation, the enclosure formed by the first andsecond portions 28, 30 of the alignment box can be substantially squareor rectangular in cross-sectional shape. For example, the area formed bythe enclosure can be approximately 12 inches by 12 inches, though othersize and shape enclosures are of course contemplated.

In one aspect, the downstream alignment stunner 14 can define at leastone opening and/or comprise at least nozzle 34 in fluid communicationwith a fluid source that is configured to direct a first stream of fluidin a desired direction. For example, the alignment stunner can be apoultry (“rain”) stunner as described in U.S. Pat. No. 7,740,527,incorporated herein by reference in its entirety. In another aspect andas illustrated in FIG. 2, the alignment stunner comprises at least onefirst opening and/or nozzle 34 that is configured to direct a firststream of fluid into at least a portion of the alignment box 26 and/orthe upper surface 20 of the alignment conveyor 12. As can beappreciated, there can be a plurality of openings and/or nozzles influid communication with the fluid source that are configured to directat least a first stream of fluid into at least a portion of the of thealignment box and/or the upper surface of the alignment conveyor. Thefirst opening and/or nozzle 34 can be coupled directly to the fluidsource, or they can be connected to several distinct fluid sources. Itis also contemplated that the alignment stunner 14 can comprise amanifold or at least one spray bar 36, which is coupled to the fluidsource and feeds the plurality of first openings and/or nozzles definedin the spray bar. In one aspect, the plurality of openings and/ornozzles 34 of the spray bar 36 can be configured to allow fluid to exitthe spray bar in a desired direction and flowrate. In another aspect,the openings and/or nozzles of the spray bar can be evenly spaced alongthe length of the spray bar such that a plurality of streams 37 of fluidexit the spray bar 36 in the desired direction and flowrate.

In one aspect, the alignment stunner can further comprise a screen orslotted cover 25 configured to allow the fluid to pass through thecover, while forcing the poultry to position its head below the cover.For example, the cover 25 can define a plurality of slots, each slotaligned with an opening or nozzle 34 of the alignment stunner such thatfluid directed from each nozzle passes through the slot beforecontacting the poultry.

In one aspect, the spray bar 36 can be an oscillating spray bar, capableof rotation about and between a first spray bar position, in which fluidexits the spray bar in a first desired direction relative to theconveyor plane of the alignment conveyor 12, and a second spray barposition, in which fluid exits the spray bar in a second desireddirection (different from the first desired direction) relative to theconveyor plane of the alignment conveyor. In the first desireddirection, the plurality of streams 37 of fluid contact the alignmentconveyor 12 generally about the second side 24 of the alignment conveyorand, in the second desired direction, the plurality of streams 37 offluid contact the alignment conveyor 12 generally away from the secondside of the alignment conveyor. Thus, in operation, when the spray barrotates from the first spray bar position to the second spray barposition, the plurality of streams 37 of fluid contacting the alignmentconveyor 12 moves from the second side 24 of the alignment conveyor 12and towards the first side 22 of the alignment conveyor.

Referring again to FIG. 1, when viewed from above, the spray bar 36 ofthe alignment stunner 14 can be positioned at an acute angle relative tothe alignment conveyor axis. In this aspect, the flow of fluid from thealignment stunner can progressively urge the bird from the alignmentconveyor 12 toward the articulated hanging box 16. Alternatively, thespray bar of the alignment stunner can be positioned substantiallyparallel to the alignment conveyor axis.

Optionally, in one aspect and as shown in FIG. 1, the alignment stunner14 can comprise a plurality of spray bars 36. In this aspect, a firstspray bar of the plurality of spray bars can be positioned at an acuteangle relative to the alignment conveyor axis and a second spray bar ofthe plurality of spray bars can be positioned substantially parallel tothe axis of the alignment conveyor 12. It is of course contemplated thatany number of spray bars can be positioned substantially parallel to thealignment conveyor axis or at an acute angle relative to the alignmentconveyor axis. It is also contemplated that at least one spray bar canbe a conventional spray bar for spraying a fluid, and at least one spraybar can be a spray bar electrically coupled to a power source asdescribed in U.S. Pat. No. 7,740,527. In another aspect, at least onespray bar can comprise a constant current power supply configured toregulate the amount of electrical current directed to each bird at apredetermined current level.

The hanging box 16 is illustrated in FIGS. 3, 4 and 7. In one aspect,the hanging box can comprise a lower surface 38, a pair of opposed sides40, a means for immobilizing 42 the bird 44, and a rear wall 46 defininga rear wall aperture 48. In another aspect, the pair of opposed sidescan be movable sides extending away from the lower surface. In stillanother aspect, the pair of opposed sides can be movable about andbetween a first side position, in which the pair of opposed sides arespaced from each other a first predetermined distance, and a second sideposition in which the pair of opposed sides are spaced from each other asecond predetermined distance that is less than the first predetermineddistance. Thus, in this aspect, the distance between the opposed sides40 can vary. For example, the distance between the opposed sides can begreater than 12 inches, about 12 inches, 11 inches, 10 inches, 9 inches,8 inches, 7 inches, 6 inches, 5 inches, 4 inches, 3 inches, 2 inches, 1inch, less than 1 inch, or any distance in between as desired. Inanother aspect, the lower surface 38 can be sized so that the legs 52 ofthe bird extend beyond the lower surface 38 when the bird is grasped bythe hanging box, as shown in FIG. 4 and described more fully below.

The means for immobilizing 42 the bird 44 can be comprise a means forimmobilizing the legs 52 of the bird. In one aspect, the means forimmobilizing the bird can comprise a pair of locking arms 50.Optionally, each locking arm of the pair of locking arms can besubstantially L-shaped, substantially J-shaped, triangularly-shaped andthe like. In one aspect, the locking arms can be movable about andbetween a first arm position, in which at least a portion of eachlocking arm is positioned below the lower surface 38 of the hanging box16, and a second arm position in which at least a portion of eachlocking arm is positioned above the lower surface. In the second armposition, a notch and/or portion of the locking arm 50 can at leastpartially surround the leg 52 of the bird 44, thereby holding the birdin place on the lower surface of the hanging box.

In one aspect, the hanging box 16 can be an articulated hanging box,capable of rotating about and between a first box position, in which thelower surface 38 of the hanging box is substantially parallel to theplane of the alignment conveyor 12, and a second box position, in whichthe lower surface of the hanging box 16 is at an acute angle relative tothe plane of the alignment conveyor. In another aspect, the lowersurface of the hanging box can be movable from a first surface positionin which the lower surface of the hanging box is substantially parallelto the floor of the processing facility and a second surface position inwhich the lower surface 38 is at an acute angle relative to the floor ofthe processing facility. In this aspect, in the first surface position,a portion of the lower surface can extend beyond the edge of the opposedsides 40 of the hanging box, illustrated in FIG. 4. In the secondsurface position, a portion of the lower surface 38 can be moved so thatthe lower surface 38 does not extend beyond the edge of the opposedsides of the hanging box 16, as illustrated in FIG. 5.

Referring again to FIG. 2, the hanging box 16 can be guided through theprocessing facility with at least one rail and/or chain 54. In oneaspect, at least a portion of the at least one rail and/or chain can bepositioned substantially parallel to the alignment conveyor 12, and atleast a portion of the at least one rail and/or chain can be positionedadjacent to a conventional picking line 56 (as shown in FIG. 1)configured to move the plurality of shackles 18 through the processingfacility. In another aspect, when the hanging box is positionedsubstantially parallel to the alignment conveyor 12, at least a portionof the lower surface 38 of the hanging box 16 can at least partiallyoverlie the upper surface 20 of the alignment conveyor. As can beappreciated, conventional gears, motors, cams, and the like can beutilized to urge movement of the hanging box 16 as desired. In anotheraspect, the hanging box can move at a hanging box speed that issubstantially the same as the alignment conveyor speed.

In one aspect, the vacuum system 17 can comprise a vacuum pump, a tube,a slot and the like such that the vacuum system is configured to exert avacuum force on an object. Referring to FIG. 8, the vacuum system can bepositioned adjacent to and/or near the rear wall 46 of the at least onehanging box 16. In this position, the vacuum force exerted by the vacuumsystem can extend through the rear wall aperture 48 defined in the rearwall. In another aspect, the vacuum system 17 can be configured to exerta vacuum force large enough such that an object positioned in thehanging box 16, such as a bird 44 and the like, can be urged towardand/or through the rear wall aperture. In a further aspect, the vacuumsystem can be sized so that the vacuum system is positioned adjacent toand/or near the rear wall of a plurality of hanging boxes 16. Forexample, a slot of the vacuum system 17 can be sized so that the slot ispositioned adjacent the rear wall aperture of a plurality of hangingboxes. In this example then, as the hanging box moves at the hanging boxspeed, the vacuum force can be exerted through the rear wall aperture 48of an individual hanging box for a predetermined period of time.

The shackle 18 is illustrated in FIGS. 5 and 6, according to variousaspects. In one aspect, the shackle can comprise a central member 58 andan outer perimeter member 60. As illustrated in FIG. 6, a proximal endof the central member 58 can be attached to the outer perimeter member60, and a distal end of the central member can extend away from theperimeter member and can be configured for attachment to a picking line.Two inner members 62 can be spaced from the outer perimeter member andcan cooperate with the outer perimeter member 60 to create a pair ofslots 67. In another aspect, at least a portion of the inner members cantaper towards the outer perimeter member. In still another aspect, atleast a portion of the inner members can be spaced from the outerperimeter member a predetermined distance so that the slots are sized toreceive the legs of the bird. In one aspect, a central cavity 63 can bedefined by a portion of the outer perimeter member, the central cavitybeing configured to allow the legs of the bird to be inserted into theshackle 18. In another aspect, the shackle can further comprise a rollerand/or a slide 65. The roller and/or slide can be configured to matinglyengage a groove defined in the hanging box 16 to improve alignment ofthe shackle 18 and the hanging box.

In one aspect, the system 10 can further comprise at least one scaleand/or load cell configured to weigh each bird. For example, eachshackle 18 could be coupled to a scale. In another aspect, the systemcan further comprise a control system such as a computer and/orprocessor coupled to at least one sensor and/or the at least one scale.In this aspect, the at least one sensor can be configured to sense thepresence and/or position of a bird. Thus, for example, the sensor cansense the presence of a bird in an alignment box 26 and the computer canspeed up or slow down the speed of the alignment conveyor 12, thehanging box 16 and/or the speed at which the shackle 18 is moving basedat least in part upon the presence of the poultry. In other aspects, theat least one sensor can sense the location and/or position of thealignment conveyor, the alignment stunner, the hanging box, the shackle,and their respective components. The computer can be programmed to takepredetermined actions based upon the readings received from the at leastone sensor.

The system 10 for hanging live poultry can be formed from conventionalmaterials, such as for example and without limitation, polymericmaterials and/or stainless steel.

In order to use the system 10 for hanging live poultry, in one aspect,it is contemplated that the birds can be fed to the alignment conveyor12 by conventional means. For example and without limitation, the birdscan be loaded from delivery trucks into a hopper or other storagedevice. The hopper can, for example and referring again to FIG. 1, feedor otherwise urge the birds to a filing conveyor 64 which can move thebirds to the alignment conveyor. Optionally, it is contemplated that thebirds can be fed directly to the alignment conveyor 12 without the needfor a hopper and/or the filing conveyor.

As the birds are urged onto the alignment conveyor 12, the first portion28 of the alignment box 26 can extend upwards from the alignmentconveyor preventing the bird from walking on the alignment conveyor pastthe first portion. The alignment conveyor can have a predetermined speedthat can be adjusted manually and/or automatically based on factors suchas the number of poultry to be processed, the size of the poultry andthe like. As the alignment conveyor travels in the alignment conveyordirection towards the alignment stunner 14, the second portion 30 of thealignment box can rotate to a position behind the bird, therebyenclosing the bird in the enclosure 32 having a side opening.

In one aspect, a hanging box 16 can have a predetermined speed and canbe positioned so that the pair of opposed sides 40 of the hanging boxare adjacent the enclosure 32 of the alignment box 26 and aresubstantially aligned with the first and second portions 28, 30 of thealignment box as the alignment box travels in the alignment conveyordirection. For example and with reference to FIG. 1, a hanging box axisA_(H) can be substantially coaxially aligned with an alignment box axisA_(A) for a predetermined amount of time and/or a predetermined distanceas the alignment box travels in the alignment conveyor direction. Thehanging box speed and direction can be substantially the same as thealignment conveyor speed and direction so that the alignment box and thehanging box are positioned adjacent each other for a predeterminedamount of time. Thus, as illustrated in FIG. 2, the opposed sides 40 ofthe hanging box and the first and second portions 28, 30 of thealignment box can cooperate to form a substantially enclosed area 66 forthe bird, except for the rear wall aperture 48 defined in the rear wall46 of the hanging box 16.

The substantially enclosed area 66 can then travel toward the alignmentstunner 14 with the bird 44 enclosed therein. Because poultry by naturedo not like to be sprayed with a fluid, such as water, birds will turnaway from a fluid source and can attempt to walk away from the fluidsource. If the fluid is electrified or if the fluid is cold, the birdscan attempt to walk away from the fluid source more quickly. As thesubstantially enclosed area 66 travels under the spray bar 36 of thealignment stunner 14, the angle of the spray bar relative to thealignment conveyor direction and/or the oscillation of the spray bar cancause the bird to walk or be urged towards the first side 22 of thealignment conveyor 12 and into the hanging box 16. In a further attemptto avoid the water, the bird can insert his head into the rear wallaperture 48. Birds that are not alive when conveyed to the alignmentstunner will not be able to move towards the first side of the conveyor,and thus will not be able to move into the hanging box. These dead birdscan remain on the alignment conveyor until reaching the end on thealignment conveyor where they can be dropped off the conveyor into acontainer for disposal.

In one aspect, the opposed sides 40 of the hanging box 16 can move fromthe first side position, in which the opposed sides are substantiallyaligned with the first and second portions 28, 30 of the alignment box26, to the second side position having a smaller distance between theopposed sides than the first position. In another aspect, the opposedsides of the hanging box can move from the first side position to thesecond side position as the bird is under the spray bar 36 of thealignment stunner, though it is contemplated that the opposed sides ofthe hanging box can move after the bird has passed under the spray bar.In one aspect, the second side position can be sized so that in thesecond side position, each of the opposed sides of the hanging box 16contacts the body of the bird 44. For example, in the second sideposition, the opposed sides 40 can be about 6 inches apart from eachother. Thus, the bird can be contacted by the opposed sides of thehanging box with at least a portion of the head of the bird extendingthrough the rear wall aperture 48.

The bird can then be conveyed to a spray bar 36 configured to stun thebird. For example, the spray bar can be electrically coupled to a powersource so that the spray directed towards the bird is electrified. Inanother example, the spray bar can spray cold or chilled fluid towardsthe bird in order to stun the bird. After the bird has been stunned, themeans for immobilizing 42 the legs of the bird, such as the locking arms50, can be moved from the first arm position to the second arm position,thereby holding the legs of the bird in place. The hanging box 16 canthen articulate from the first box position to the second box position,in which the lower surface 38 of the hanging box 16 is at an acute anglerelative to the plane of the alignment conveyor. After the bird has beenimmobilized, the lower surface of the hanging box 16 can rotate to thesecond surface position, wherein the legs of the bird can extend beyondedge of the sides 40 of the hanging box while the lower surface 38 doesnot extend beyond the edge of the opposed sides of the hanging box 16.

As can be appreciated, after the bird has been grasped by the hangingbox, the hanging box can travel away from the alignment conveyor 12. Ascan also be appreciated, the steps to grasp the bird can be accomplishedin other order than described above. For example, the means forimmobilizing 42 the legs of the bird can move to the second arm positionprior to stunning the bird. In another example, the hanging box 16 canarticulate to the second box position prior to locking the legs of thebird.

The hanging box 16 with the bird grasped therein can be brought adjacentto the picking line 56. As illustrated in FIG. 1, in one aspect, thepicking line and the hanging box can be brought adjacent to each otherin an area where the at least one rail and/or chain 54 is curved. Forexample, an inner radius of the at least one rail and/or chain can bealigned with an outer radius of the picking line so that the hanging box16 can be aligned with a shackle 18. By placing the picking line and thehanging box adjacent to each other in a curved area, different spacingbetween each hanging box and each shackle can be achieved. For example,the shackles can be spaced about 6 inches apart on the picking line,while the hanging boxes can be spaced about 12 inches apart.

Because the hanging box is in the second box position, the legs of thebird can be in a plane above the two inner members 62 of the shackle.Upon alignment of the hanging box 16 and the shackle 18, the hanging boxcan articulate towards the first box position, thereby lowering the legsof the bird into the central cavity 63 of the shackle. As the hangingbox continues to articulate towards the first box position, each leg ofthe bird can be lowered into a respective slot 67 formed between theinner members 62 and the outer perimeter member 60 of the shackle 18.The opposed sides 40 of the hanging box can rotate toward the first sideposition and the means for immobilizing 42 the legs of the bird can bemoved from the second arm position to the first arm position, therebyreleasing the hanging box's grasp on the bird and hanging the bird inthe shackle. The picking line can then transport the bird through theprocessing facility for conventional processing.

In order to use the system 10 for hanging live poultry, in anotheraspect and as illustrated in FIG. 8, it is contemplated that the birdscan be fed to the alignment conveyor 12 by conventional means. Forexample and without limitation, the birds can be loaded from deliverytrucks into a hopper or other storage device. The hopper can, forexample, feed or otherwise urge the birds to a filing conveyor 64 whichcan move the birds to the alignment conveyor. Optionally, it iscontemplated that the birds can be fed directly to the alignmentconveyor 12 without the need for a hopper and/or the filing conveyor.

As the birds 44 are urged onto the alignment conveyor 12, the firstportion 28 of the alignment box 26 can extend upwards from the alignmentconveyor preventing the bird from walking on the alignment conveyor pastthe first portion. The alignment conveyor can have a predetermined speedthat can be adjusted manually and/or automatically based on factors suchas the number of poultry to be processed, the size of the poultry andthe like. As the alignment conveyor travels in the alignment conveyordirection towards the alignment stunner 14, the second portion 30 of thealignment box can rotate to a position behind the bird, therebyenclosing the bird in the enclosure 32 having a side opening.

In one aspect, a hanging box 16 can have a predetermined speed and canbe positioned so that the pair of opposed sides 40 of the hanging boxare adjacent the enclosure 32 of the alignment box 26 and aresubstantially aligned with the first and second portions 28, 30 of thealignment box as the alignment box travels in the alignment conveyordirection. The hanging box speed and direction can be substantially thesame as the alignment conveyor speed and direction so that the alignmentbox and the hanging box are positioned adjacent each other for apredetermined amount of time. Thus, as illustrated in FIG. 2, theopposed sides 40 of the hanging box and the first and second portions28, 30 of the alignment box can cooperate to form the substantiallyenclosed area 66 for the bird, except for the rear wall aperture 48defined in the rear wall 46 of the hanging box 16.

The substantially enclosed area 66 can then travel toward the alignmentstunner 14 with the bird 44 enclosed therein. Because poultry by naturedo not like to be sprayed with a fluid, such as water, birds will turnaway from a fluid source and can attempt to walk away from the fluidsource. If the fluid is electrified or if the fluid is cold, the birdscan attempt to walk away from the fluid source more quickly. As thesubstantially enclosed area 66 travels under the spray bar 36 of thealignment stunner 14, the angle of the spray bar relative to thealignment conveyor direction and/or the oscillation of the spray bar cancause the bird to walk or be urged towards the first side 22 of thealignment conveyor 12 and into the hanging box 16. Birds that are notalive when conveyed to the alignment stunner will not be able to movetowards the first side of the conveyor, and thus will not be able tomove into the hanging box. These dead birds can remain on the alignmentconveyor until reaching the end on the alignment conveyor where they canbe dropped off the conveyor into a container for disposal.

In a further attempt to avoid the water, the bird 44 can insert his headinto the rear wall aperture 48. In one aspect, the vacuum force from thevacuum system 17 can urge the bird towards the rear wall 46 of thehanging box. Optionally, the vacuum force from the vacuum system 17 canurge the head of the bird through the rear wall aperture 48 defined inthe rear wall.

The bird 44, with its head positioned in the rear wall aperture 48, canthen be stunned or killed. In one aspect, the bird can be conveyed tothe spray bar 36 configured to stun the bird. For example, the spray barcan be electrically coupled to a power source so that the spray directedtowards the bird is electrified. In another example, the spray bar canspray cold or chilled fluid towards the bird in order to stun the bird.

After the bird 44 has been stunned or killed with its head positioned inthe rear wall aperture 48, the bird can be positioned in a shackle 18 ofthe picking line 56 manually by a user or automatically.

If the bird is to be positioned in a shackle 18 of the picking line 56automatically, the means for immobilizing 42 the legs of the bird, suchas the locking arms 50, can be moved from the first arm position to thesecond arm position, thereby holding the legs of the bird in place. Thehanging box 16 can then articulate from the first box position to thesecond box position, in which the lower surface 38 of the hanging box 16is at an acute angle relative to the plane of the alignment conveyor.After the bird has been immobilized, the lower surface of the hangingbox 16 can rotate to the second surface position, wherein the legs ofthe bird can extend beyond edge of the sides 40 of the hanging box whilethe lower surface 38 does not extend beyond the edge of the opposedsides of the hanging box 16.

As can be appreciated, after the bird has been grasped by the hangingbox 16, the hanging box can travel away from the alignment conveyor 12.As can also be appreciated, the steps to grasp the bird can beaccomplished in other order than described above. For example, the meansfor immobilizing 42 the legs of the bird can move to the second armposition prior to stunning the bird. In another example, the hanging box16 can articulate to the second box position prior to locking the legsof the bird.

The hanging box 16 with the bird grasped therein can be brought adjacentto the picking line 56. As illustrated in FIG. 1, in one aspect, thepicking line and the hanging box can be brought adjacent to each otherin an area where the at least one rail and/or chain 54 is curved. Forexample, an inner radius of the at least one rail and/or chain can bealigned with an outer radius of the picking line so that the hanging box16 can be aligned with a shackle 18. By placing the picking line and thehanging box adjacent to each other in a curved area, different spacingbetween each hanging box and each shackle can be achieved. For example,the shackles can be spaced about 6 inches apart on the picking line,while the hanging boxes can be spaced about 12 inches apart.

Because the hanging box is in the second box position, the legs of thebird can be in a plane above the two inner members 62 of the shackle.Upon alignment of the hanging box 16 and the shackle 18, the hanging boxcan articulate towards the first box position, thereby lowering the legsof the bird into the central cavity 63 of the shackle. As the hangingbox continues to articulate towards the first box position, each leg ofthe bird can be lowered into a respective slot 67 formed between theinner members 62 and the outer perimeter member 60 of the shackle 18.The opposed sides 40 of the hanging box can rotate toward the first sideposition and the means for immobilizing 42 the legs of the bird can bemoved from the second arm position to the first arm position, therebyreleasing the hanging box's grasp on the bird and hanging the bird inthe shackle. The picking line can then transport the bird through theprocessing facility for conventional processing.

Although several embodiments of the invention have been disclosed in theforegoing specification, it is understood by those skilled in the artthat many modifications and other embodiments of the invention will cometo mind to which the invention pertains, having the benefit of theteaching presented in the foregoing description and associated drawings.It is thus understood that the invention is not limited to the specificembodiments disclosed hereinabove, and that many modifications and otherembodiments are intended to be included within the scope of the appendedclaims. Moreover, although specific terms are employed herein, as wellas in the claims which follow, they are used only in a generic anddescriptive sense, and not for the purposes of limiting the describedinvention, nor the claims which follow.

1. An automated system for hanging poultry, comprising: at least onehanging box configured to immobilize the poultry and movable in aconveyor direction, the at least one hanging box comprising a lowersurface, a pair of opposed sides, and a rear wall defining a rear wallaperture; an alignment stunner comprising a fluid source that provides astream of fluid, the alignment stunner configured for urging the poultrytoward the rear wall of the at least one hanging box; a vacuum systemcomprising at least a vacuum pump and a vacuum slot, wherein a portionof the vacuum slot is positioned adjacent to the rear wall of the atleast one hanging box, and wherein the vacuum system exerts a vacuumforce through the rear wall aperture to urge a portion of the poultrytoward the rear wall aperture; and a shackle configured to grasp aportion of the poultry, the shackle being positioned in a picking lineconfigured to carry the grasped poultry for further processing, whereinthe hanging box positions the poultry into the shackle.
 2. The automatedsystem for hanging poultry of claim 1, wherein the vacuum system exertsa vacuum force through the rear wall aperture to urge a portion of thepoultry through the rear wall aperture.
 3. The automated system forhanging poultry of claim 1, wherein the at least one hanging boxcomprises a plurality of hanging boxes, and wherein the vacuum slot issized so that the slot is positioned adjacent the rear wall aperture ofa plurality of hanging boxes.
 4. The automated system for hangingpoultry of claim 1, further comprising an alignment conveyor having anupper surface positioned in an alignment conveyor plane and movable inan alignment conveyor direction, wherein the alignment conveyorcomprises at least one alignment box positioned on an upper surface ofthe alignment conveyor that is configured to receive poultry, whereinthe alignment box comprises a first portion and a separate secondportion that form an enclosure defining a side opening and wherein thefirst and second portions of the alignment box extend upwardly away fromthe conveyor plane of the alignment conveyor.
 5. The automated systemfor hanging poultry of claim 1, wherein the alignment stunner furthercomprises at least one spray bar.
 6. The automated system for hangingpoultry of claim 5, wherein the at least one spray bar is an oscillatingspray bar, capable of rotation about and between a first spray barposition, in which fluid exits the at least one spray bar in a firstdesired direction relative to the conveyor plane of the alignmentconveyor, and a second spray bar position, in which fluid exits the atleast one spray bar in a second desired direction that is different fromthe first desired direction.
 7. The automated system for hanging poultryof claim 5, wherein the at least one spray bar comprises a plurality ofspray bars, and wherein at least one spray bar of the plurality of spraybars is positioned at an acute angle relative to an alignment conveyoraxis.
 8. The automated system for hanging poultry of claim 7, wherein atleast one spray bar of the plurality of spray bars is electricallycoupled to a power source so that fluid exiting the at least one spraybar is electrified.
 9. The automated system for hanging poultry of claim1, wherein the alignment stunner is positioned relative to the at leastone hanging box to urge the poultry to position its head in the rearwall aperture of the hanging box.
 10. The automated system for hangingpoultry of claim 1, wherein the pair of opposed sides of the at leastone hanging box are movable relative to each other and extend away fromthe lower surface.
 11. The automated system for hanging poultry of claim10, wherein the pair of opposed sides are movable about and between afirst side position, in which the pair of opposed sides are spaced fromeach other a first predetermined distance, and a second side position inwhich the pair of opposed sides are spaced from each other a secondpredetermined distance that is less than the first predetermineddistance.
 12. The automated system for hanging poultry of claim 1,wherein the at least one hanging box further comprises a pair of lockingarms movable about and between a first arm position, in which at least aportion of each locking arm is positioned below the lower surface of thehanging box, and a second arm position in which at least a portion ofeach locking arm is positioned above the lower surface of the hangingbox.
 13. The automated system for hanging poultry of claim 12, whereineach arm of the pair of locking arms is substantially L-shaped.
 14. Theautomated system for hanging poultry of claim 1, wherein the at leastone hanging box is rotatable about and between a first box position, inwhich the lower surface of the hanging box is substantially parallel toa floor on which the system is placed, and a second box position, inwhich the lower surface of the hanging box is at an acute angle relativeto the floor.
 15. The automated system for hanging poultry of claim 14,wherein the at least one hanging box positions the poultry into theshackle as the hanging box rotates from the second box position towardsthe first box position.
 16. The automated system for hanging poultry ofclaim 1, further comprising a control system coupled to at least onesensor.
 17. The automated system for hanging poultry of claim 16,wherein the at least one sensor is configured to sense the presence ofthe poultry at a predetermined position in the system.
 18. The automatedsystem for hanging poultry of claim 17, wherein the at least one sensoris configured to sense the presence of the poultry in the hanging box,and wherein the control system selectively adjusts a speed of the atleast one hanging box based at least in part upon the presence of thepoultry.
 19. A method for hanging poultry in a shackle automatically,comprising: providing a hanging box configured to immobilize the poultryand movable in a conveyor direction, the hanging box comprising a lowersurface, a pair of opposed sides, and a rear wall; providing analignment stunner for urging the poultry toward the rear wall of thehanging box, the alignment stunner defining at least one fluid openingin fluid communication with a fluid source that is configured to directat least a first stream of fluid in a desired direction towards theupper surface of the alignment conveyor; providing a vacuum systemcomprising at least a vacuum pump and a vacuum slot, wherein a portionof the vacuum slot is positioned adjacent to the rear wall of thehanging box, and wherein the vacuum system exerts a vacuum force throughthe rear wall aperture to urge a portion of the poultry toward the rearwall aperture; providing a shackle configured to grasp a portion of thepoultry, the shackle being positioned in a picking line configured tocarry the grasped poultry for further processing; inserting poultry intothe hanging box; and activating the hanging box such that the hangingbox conveys the poultry to the alignment stunner, wherein the alignmentstunner urges the poultry toward the rear wall of the hanging box,wherein the vacuum system urges a portion of the poultry through therear wall aperture, and wherein the hanging box contacts the poultry andinserts the poultry into the shackle.
 20. The method of hanging poultryof claim 19, wherein the hanging box further comprises a pair of lockingarms movable about and between a first arm position, in which at least aportion of each locking arm is positioned below the lower surface of thehanging box, and a second arm position in which at least a portion ofeach locking arm is positioned above the lower surface of the hangingbox.